SDC21xx. 2x20A or 1x40A High Performance Dual Channel Brushed DC Motor Controller with USB and CAN Interface

Transcription

1 SDC21xx 2x20A or 1x40A High Performance Dual Channel Brushed DC Motor Controller with USB and CAN Interface Fitting into a very compact 73x73mm enclosure, Roboteq s SDC21xx controller is designed to convert commands received from an RC radio, Analog Joystick, wireless modem, PC (via RS232 or USB) or microcomputer into high voltage and high current out put for driving one or two DC motors. A CAN bus interface allows up to 127 controllers to communicate at up to 1Mbit/s on a single twisted pair. The controller features a high-performance 32-bit microcomputer and quadrature encoder inputs to perform advanced motion control algorithms in Open Loop or Close Loop (Speed or Position) modes. The SDC21xx features several Analog, Pulse and Digital I/Os which can be remapped as command or feedback inputs, limit switches, or many other functions. For mobile robotic applications, the controller s two motor chan nels can either be operated independently or mixed to set the direction and rotation of a vehicle by coordinating the motion of each motor. Numerous safety features are incorporated into the controller to ensure reliable and safe operation. The controller s operation can be extensively automated and customized by utilizing user generated Basic Language programs. The controller can be repro grammed in the field with the latest features by downloading new operating software from Roboteq. Applications Industrial Automation Tracking, Pan & Tilt systems Small to mid-size Terrestrial and Underwater Robotic Vehicles Automatic Guided Vehicles (AGV) Automated machines Telepresence Systems Animatronics Features List USB, RS232, 0-5V Analog, or Pulse (RC radio) command modes CAN bus interface up to 1Mbit/s Auto switch between USB, RS232 (12V levels or noninverted TTL levels), CAN, Analog, or Pulse based on userdefined priority Built-in, high-current power drivers for two brushed DC motors at up to 20A output per channel Available in single channel version up to 40A Full forward and reverse control on each channel. Four quad rant operation. Supports regeneration Built-in programming language for automation and customization Operates from a single power source Programmable current limit for each channel up to 2x20A or 1x40A for protecting controller, motors, wiring and battery Up to six Analog Inputs for use as command and/or feedback Up to six Pulse Length, Duty Cycle or Frequency Inputs for use as command and/or feedback Up to six Digital Inputs for use as Deadman Switch, Limit Switch, Emergency stop or user inputs Dual Quadrature Encoder inputs with 32-bit counters Two general purpose 24V, 1A output for brake release or accessories Selectable min/max, center and deadband in Pulse and Analog modes Selectable exponentiation factors for each command inputs Trigger action if Analog, Pulse or Encoder capture are outside user selectable range (soft limit switches) Open loop or closed loop speed control operation SDC21xx Motor Controller Datasheet 1

2 Closed loop position control with analog or pulse/frequency feedback Precise speed and position control when Encoder feedback is used PID control loop with separate gains for each channel Optional Mixed control (sum and difference) for tank-like steering Configurable Data Logging of operating parameters on RS232 Output for telemetry or analysis Built-in Battery Voltage and Temperature sensors Power Control header for turning On or Off the controller from external microcomputer or switch No consumption by output stage when motors stopped Regulated 5V output for powering Encoders, RC radio, RF Modem or microcomputer Separate Programmable acceleration and deceleration for each motor Separate Programmable maximum forward and reverse power Support for CANopen and two simplified CAN protocols Direct connection to multi-channel 2.4GHz RC satellite receiver Ultra-efficient 10 mohm ON resistance MOSFETs Stall detection and selectable triggered action if Amps is outside user-selected range Overvoltage and Undervoltage protection Programmable Watchdog for automatic motor shutdown in case of command loss Overtemperature protection Diagnostic LED indicators Efficient heat sinking using conduction bottom plate. Operates without a fan in most applications Power wiring via terminal strip wires up to AWG (70mm) L, 2.76 W (70mm), 0.78 (20mm) H -40o to +85o C operating environment 4.2oz (120g) Easy configuration, tuning and monitory using provided PC utility Field upgradeable software for installing latest features via the Internet Orderable Product References TABLE 1. Reference Number of Channels Amps/Channel Volts Ethernet Resolver USB SDC No No Yes SDC No No Yes SDC2130S No No Yes SDC2160S No No Yes 2 SDC21xx Motor Controller Datasheet Version 2.2 January 23, 2018

3 Power Wires Identifications and Connection Important Safety Disclaimer Dangerous uncontrolled motor runaway conditions can occur for a number of reasons, including, but not limited to: command or feedback wiring failure, configuration error, faulty firmware, errors in user script or user program, or controller hardware failure. The user must assume that such failures can occur and must make their system safe in all conditions. Roboteq will not be liable in case of damage or injury as a result of product misuse or failure. Power Wires Identifications and Connection Power connections are made through a six position screw terminal. GND wrctrl 8 1 Radio Connecto 15 9 USB Connector FIGURE 1. Controller Top View Layout IO Connector SDC21xx Motor Controller Datasheet 3

4 Figure 2, below, shows how to wire the dual-channel controller and how to turn power On and Off. F2 1A SW1 Main On/Off Switch 1A Note 1 PwrCtrl Ground M1+ Backup Battery Motor 1 Diode >10A Resistor 1K, 0.5W Note 3 Note 2 M1- M2+ F1 Note 4 SW2 Emergency Contactor or Cut-off Switch VMot M2- Motor Main Battery Ground I/O Connector Note 5 Do not Connect! FIGURE 2. Powering the Controller. Thick lines identify MANDATORY connections Important Warning Mandatory Connections Carefully follow the wiring instructions provided in the Power Connection section of the User Manual. The information on this datasheet is only a summary. It is imperative that the controller is connected, as shown in Figure 2, above, in order to ensure a safe and trou ble-free operation. All connections shown as thick black lines line are mandatory. The controller must be powered On/Off using switch SW1on the Power Control Header. Emergency Switch or Contactor The battery must be connected in permanence to the controller s VMot power via an input emergency switch or contactor SW2 as additional safety measure. The user must be able to deactivate the switch or contactor at any time, independently of the controller state. Precautions and Optional Connections Note 1: An optional backup battery to ensure motor operation with weak or discharged battery. Note 2: Use precharge 1K Resistor to prevent switch arcing. Note 3: Insert a high-current diode to ensure a return path to the battery during regeneration in case the fuse is blown. Note 4: Users have the option to ground the VMot terminal when the controller is Off. It is recommended that users do this if there is any concern that the motors could be made to spin and generate voltage in excess of excess of 10V. Note 5: Beware not to create a path from the ground pins on the I/O connector and the battery s minus terminal. 4 SDC21xx Motor Controller Datasheet Version 2.2 January 23, 2018

5 Use of Safety Contactor for Critical Applications Use of Safety Contactor for Critical Applications An external safety contactor must be used in any application where damage to property or injury to person can occur because of uncontrolled motor operation resulting from failure in the controller s power output stage. Diode >20A F2 1A SW1 Main On/Off Switch 1A Resistor 1K, 0.5W PwrCtrl Ground F1 to +40V Max Digital Out VMot I/O Connector + - Ground Main Battery FIGURE 3. Contactor Wiring Diagram The contactor coil must be connected to a digital output configured to activate when No MOSFET Failure. The controller will automatically deactivate the coil if the output is expected to be off and battery current of 500mA or more is measured for more than 0.5s. This circuit will not protect against other sources of failure such as those described in the Important Safety Disclaimer on Page 3. Single Channel Wiring The single channel version of the controller (SDC2130S and SDC2160S) require that the output be parallel and that the load be wired, as shown in Figure 4, below. M M1+ M1- M2+ M2- FIGURE 4. SDC2130S and SDC2160S Wiring Diagram Important Warning This wiring in Figure 4 is only possible on controllers fitted with the Single Channel version of the firmware. Dual channel controllers will be damaged if wired as single channel. Verify that the PC utility identifies the con troller as SDC2130S or SDC2160S before applying power to the load. SDC21xx Motor Controller Datasheet 5

6 Controller Mounting During motor operation, the controller will generate heat that must be dissipated. The published amps rating can only be fully achieved if adequate cooling is provided. Good conduction cooling can be achieved by mounting the controller to a metallic surface, such as the chassis, cabinet, etc. Sensor and Commands Connection Connection to RC Radio, Microcomputer, Joystick and other low current sensors and actuators is done via the 15 connector located in front of 1the board. The functions 13 of many pins vary depending on user configuration. Pin assignments can be found in Table 2, below FIGURE 5. Connector Pin Locations TABLE 2. Connector Pin Power Dout Com RC Ana Dinput Enc Default Config 1 DOUT1 Unused 9 DOUT2 Unused 2 TxOut RS232Tx Data 10 RC5 ANA5 (1)(2) DIN5 ENC2A Unused 3 RxIn RS232Rx Data 11 RC4 ANA4 DIN4 Unused 4 RC1 ANA1 (1)(2) DIN1 ENC1A RCRadio1 12 RC3 ANA3 DIN3 Unused 5 GND 13 GND 6 CANL (3) 14 5VOut 7 CANH (3) 15 RC6 (1) ANA6 (2) DIN6 ENC2B Unused 6 SDC21xx Motor Controller Datasheet Version 2.2 January 23, 2018

7 Enabling Analog Commands Connector Pin Power Dout Com RC Ana Dinput Enc Default Config 8 RC2 ANA2 DIN2 ENC1B RCRadio2 Note 1: RC6, ANA5 and ANA6 present on hardware version 2.0 Note 2: On hardware version 1, ANA1 is on Pin 10 Note 3: On hardware version 1, CAN is only available on SDC21xxN Pin Assignment Changes Between v1.x and v2.x V2.x of the SDC21xx has six Analog inputs instead of four. Analog Input 1 has been moved from Pin 10 to Pin 4. If backwards compatibility is required, contact Roboteq for instruction on restoring the Version 1 pinout. Default I/O Configuration The SDC 21xx controller can be configured so that practically any Digital, Analog and RC pin can be used for any purpose. The controller s factory default configuration provides an assignment that is suitable for most applications. Figure 6, below, shows how to wire the controller to two analog potentiometers, an RC radio, and the RS232 port. It also shows how to connect the two outputs to motor brake solenoids. You may omit any connection that is not required in your application. The controller automatically arbitrates the command priorities depending on the presence of a valid command signal in the following order: 1-RS232, 2-RC Pulse, 3-None. If needed, use the Roborun+ PC Utility to change the pin assignments and the command priority order. RC Ch2 RC Ch1 2 1 RS232 Ground TxOut RxIn 8 1 Motor Brake Safety Contactor 15 9 Pot 2 Pot 1 FIGURE 6. Factory Default Pin Assignments Enabling Analog Commands CAN Bus Operation For safety reasons, the Analog command mode is disabled by default. To enable the Analog mode, use the PC utility and set Analog in Command Priority 2 or 3 (leave Serial as priority 1). Note that by default the additional securities are enabled and will prevent the motor from starting unless the potentiometer is centered, or if the voltage is below 0.25V or above 4.75V. The drawing shows suggested assignment of Pot 1 to ANA5 (ANA1 on v1.x) and Pot 2 to ANA4. Use the PC utility to enable and assign analog inputs. The controller can interface with a standard CAN Bus network using 4 possible protocols: Standard CANOpen, and three simplified proprietary schemes (MiniCAN, RawCAN and RoboCAN. Please refer to the User Manual for details. On hardware version 1.x, CAN is only available on SDC21xx. SDC21xx Motor Controller Datasheet 7

8 USB communication Use USB only for configuration, monitoring and troubleshooting. USB is not a reliable communication method when used in a electrically noisy environments and communication will not always recover after it is lost without unplugging and replugging the connector, or restarting the controller. Always prefer RS232 communication when interfacing to a computer. Serial Communication The controller has a full RS232 compatible serial interface. On v2.x, the serial port can easily be connected to devices with TTL serial using a simple resistor and diodes circuit. See user manual for details. Satellite Receiver Connection A 3-pin plug is provided for direct connection to a SP9545 miniature receiver. Status LED Flashing Patterns The controller is equipped with three LEDs. After the controller is powered on, the Power LED will tun on, indicating that the controller is On. The Status LED will be flashing at a two second interval. The flashing pattern provides operating or exception status information. Communication LED Power LED Status LED FIGURE 7. LED Identifications Idle -Waiting for Command RS232/USB Mode RC Pulse Mode Analog Mode FIGURE 8. Normal Operation Flashing Patterns Short Detected Overheat Under or Over Voltage Power Stage Off FIGURE 9. Exception or Fault Flashing Patterns Additional status information may be obtained by monitoring the controller with the PC utility. Note: Red/Green LED is only in hardware Version 2.0 and newer. Version 1.0 uses monochrome LED. The communica tion LED gives status information on the CAN and USB. 8 SDC21xx Motor Controller Datasheet Version 2.2 January 23, 2018

9 Secure Connection to AMP FASTON Tabs Always off: No USB, No CAN Always On: USB Active, No CAN Flashing On: No USB, CAN Enabled Flashing Off: USB Active, CAN Enabled Figure 10. Communication LED Secure Connection to AMP FASTON Tabs Power Motor and Battery connections are made via standard 250mils (6.35mm) AMP FASTON Tabs. FASTON connectors provide a high current and very secure connection, proven over decades of use in the automotive industry. For maximum current handling, use connectors for AWG10 wires recognizable by their yellow plastic insulator. FASTON connectors have an extremely tight fit and will not come off on their own. It is recommended, nevertheless, that the wiring is made so that the cables are never pulling the connector outward. Frequent disconnects and reconnects will eventually loosen the connector s grip on the tab. If frequent disconnection is required, consider using Positive Lock connectors from TE Connectivity or their equivalent. These connectors have a spring loaded tab latch pin that will lock into the hole of the male tab. Amps Sensors The controller has built in sensor to measure the battery amps for each channel. Motor Amps are calculated. Motor Amps precision decreases at PWM levels below 20%. Motor Amps are not measured and reported as 0 when the PWM output is at 0%. Electrical Specifications Absolute Maximum Values TABLE 3. The values in the table below should never be exceeded. Permanent damage to the controller may result. Parameter Measure point Models Min Typical Max Units Battery Leads Voltage Ground to VMot SDC Volts Reverse Voltage on Bat tery Leads Motor Leads Voltage SDC Volts Ground to VMot All -1 Volts Ground to M1+, M1-, M2+, M2- SDC Volts SDC Volts Digital Output Voltage Ground to Output pins All 40 Volts SDC21xx Motor Controller Datasheet 9

10 TABLE 3. Parameter Measure point Models Min Typical Max Units Analog and Digital Inputs Voltage RS232 I/O pins Voltage Ground to any signal pin on 25 & 9-pin connectors External voltage applied to Rx/Tx pins All 30 Volts All 30 Volts Board Temperature Board ºC Humidity Board 100 (3) % Note 1: Maximum regeneration voltage in normal operation. Never inject a DC voltage from a battery or other fixed source Note 2: Non-condensing Power Stage Electrical Specifications (at 25ºC ambient) TABLE 4. Parameter Measure point Models Min Typical Max Units Battery Leads Voltage Ground to VMot SDC2130(S) 10 (1) 35 Volts Motor Leads Voltage Ground to M1+, M1-, M2+, M2- SDC2160(S) 10 (1) 62 Volts SDC2130(S) 0 (1) 35(2) Volts SDC2160(S) 0 (1) 62(2) Volts Over Voltage protection range Ground to VMot SDC2130(S) 5 30 (4) 35 Volts Under Voltage protection range SDC2160(S) 5 60 (4) 62(2) Volts Ground to VMot SDC2130(S) 0 5 (4) 35 Volts SDC2160(S) 0 5 (4) 62 Volts Idle Current Consumption VMot or Pwr Ctrl wires All (5) 100 ma ON Resistance (Excluding wire resistance) Max Current per channel for 30s Continuous Max Current per channel Current Limit range Stall Detection Amps range Stall Detection timeout range Motor Acceleration/Deceleration range VMot to M+, plus M- to Ground at 100% power. Per channel Ch1 or Ch2 Motor current Ch1 or Ch2 Motor current Ch1 or Ch2 Motor current Ch1 or Ch2 Motor current Ch1 or Ch2 Motor current SDC2130/60 20 mohm SDC2130S/60S 10 mohm SDC2130/60 20 Amps SDC2130S/60S 40 Amps SDC2130/60 15 (7) Amps SDC2130S/60S 30 (7) Amps SDC2130/ (8) 20 Amps SDC2130S/60S 1 30 (8) 40 Amps SDC2130/ (8) 20 Amps SDC2130S/60S 1 30 (8) 40 Amps All (9) milliseconds Ch1 or Ch2 All (10) milliseconds 10 SDC21xx Motor Controller Datasheet Version 2.2 January 23, 2018

11 Electrical Specifications TABLE 4. Parameter Measure point Models Min Typical Max Units Note 1: Negative voltage will cause a large surge current. Protection fuse needed if battery polarity inversion is possible Note 2: Maximum regeneration voltage in normal operation. Never inject a DC voltage from a battery or other fixed source Note 3: Minimum voltage must be present on VMot or Power Control wire Note 4: Factory default value. Adjustable in 0.1V increments Note 5: Current consumption is lower when higher voltage is applied to the controller s VMot or PwrCtrl wires Note 6: Max value is determined by current limit setting. Duration is estimated and is dependent on ambient temperature cooling condition Note 7: Estimate. Limited by heatsink temperature. Current may be higher with better cooling Note 8: Factory default value. Adjustable in 0.1A increments Note 9: Factory default value. Time in ms that Stall current must be exceeded for detection Note 10: Factory default value. Time in ms for power to go from 0 to 100% Important Warning: Be aware that regenerative braking can create high voltage at the controller s power inputs. Use the con troller only with batteries. See user manual for special precautions when using a power supply. Command, I/O and Sensor Signals Specifications TABLE 5. Parameter Measure point Min Typical Max Units Main 5V Output Voltage Ground to 5V pins on Volts 5V Output Current 5V pins on RJ45 and DSub ma Digital Output Voltage Ground to Output pins 30 Volts Digital Output Current Output pins, sink current 1 Amps Output On resistance Output pin to ground Ohm Output Short circuit threshold Output pin Amps Input Impedances AIN/DIN Input to Ground 53 kohm Digital Input 0 Level Ground to Input pins -1 1 Volts Digital Input 1 Level Ground to Input pins 3 30 Volts Analog Input Range Ground to Input pins Volts Analog Input Precision Ground to Input pins 0.5 % Analog Input Resolution Ground to Input pins 1 mv Encoder Frequency 500 khz Pulse durations Pulse inputs us Pulse repeat rate Pulse inputs Hz Pulse Capture Resolution Pulse inputs 1 us Frequency Capture Pulse inputs Hz Encoder count Internal ^9 Counts Encoder frequency Encoder input pins 1M(1)(2) Counts/s Note1: Max 30Kcounts/s on dual channel v1.x. Note 2: Enabling Encoder disables pulse capture SDC21xx Motor Controller Datasheet 11

12 Operating & Timing Specifications TABLE 6. Parameter Measure Point Min Typical Max Units Command Latency Command to output change ms PWM Frequency Ch1, Ch2 outputs (1) 20 khz Closed Loop update rate Internal 1000 Hz USB Rate USB pins 12 MBits/s RS232 baud rate Rx & Tx pins (2) Bits/s RS232 Watchdog timeout Rx pin 1 (3) ms Note 1: May be adjusted with configuration program Note 2: , 8-bit, no parity, 1 stop bit, no flow control Note 3: May be disabled with value 0 Scripting TABLE 7. Parameter Measure Point Min Typical Max Units Scripting Flash Memory Internal (1) Bytes Max Basic Language programs Internal Lines Integer Variables Internal 4096 Words (2) Boolean Variables Internal 8190 Symbols Execution Speed Internal Lines/s Note 1: 8192 in Version 1 hardware Note 2: 32-bit words Thermal Specifications TABLE 8. Parameter Measure Point Model Min Typical Max Units Board Temperature PCB All (1) ºC Thermal Protection range PCB All (2) ºC Thermal resistance Power MOSFETs to heats sink Note 1: Thermal protection will protect the controller power All 2 ºC/W Note 2: Max allowed power out starts lowering at minimum of range, down to 0 at max of range The SDC21xx uses a conduction plate at the bottom of the board for heat extraction. For best results, attach firmly with thermal compound paste against a metallic chassis so that heat transfers to the conduction plate to the chas sis. If no metallic surface is available, mount the controller on spacers so that forced or natural air flow can go over the plate surface to remove heat. 12 SDC21xx Motor Controller Datasheet Version 2.2 January 23, 2018

13 Electrical Specifications 73.0 R FIGURE 12. SDC21xx Top View and Dimensions Mechanical Specifications TABLE 9. Parameter Measure Point Min Typ Max Units Weight Board 120 (4.2) g (oz.) Power Wire Gauge Terminal strip 12 AWG FIGURE 11. SDC21xx Front View and Dimensions SDC21xx Motor Controller Datasheet 13